AB | Case History
AB FOR SMEC COGENERATION FOR THE EFFICIENCY OF A PUBLIC HEATING NETWORK TARGETING AROUND 9,000 USERS IN THE NORTH MILAN AREA
AB FOR SMEC
AB IS A PARTNER OF SMEC, TO WHICH IT SUPPLIES ENGINEERING, PRODUCTION AND MAINTENANCE OF TWO COGENERATION PLANTS INSTALLED AT THE REMOTE-CONTROLLED HEATING POWER PLANT.
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DISTRICT H Centralised combustion that is strictly controlled both in terms of efficiency and emissions. Elimination of boilers from buildings, resulting in a reduction of all relevant maintenance expenses. Greater safety thanks to the elimination of all the risks of poor functioning of the boiler, the gas line and chimney flue.
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HEATING ADVANTAGES ALL-ROUND:
USERS, LOCAL ADMINISTRATION AND THE ENVIRONMENT.
District heating is one of the most valid responses
therefore also eliminated. But the advantages for
that combines energy saving and eco-sustainability,
the user do not stop at merely economic benefits:
particularly
and
the lack of fuels and naked flames, replaced by the
industrial areas that often suffer problems caused
centralised supply of hot or heated water, make
by high polluting emissions into the atmosphere.
district heating a particularly safe system.
The possibility of eliminating thousands of individual
District heating provides a valid contribution to
boilers and developing a single, high efficiency,
improving air quality, particularly in the most badly-
centralised system to circulate hot water continues
affected urban environments. The generators used
to prove to be one of the safest and most efficient
in the cogeneration plants are extremely efficient
choices in terms of green economy. Environmental
and constantly monitored by specialised staff. This,
protection goes hand-in-hand with concrete benefits
together with the inclusion of efficient waste fume
for the user and local community as a whole.
purifiers, makes for a significant environmental
Infrastructures
individual
benefit. Clearly, savings in this sector can play an
internal heat production systems are no longer
important role in achieving local and national energy
necessary, and the costs for their maintenance are
saving policy objectives.
in
densely-populated
linked
to
urban
traditional
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THE IDEAL PROCESS TO INCREASE AND FULLY EXPLOIT THE ADVANTAGES OF REMOTE HEATING.
COGENE BELOW ARE THE SENSATIONAL FIGURES OF THE POWER PLANT IN CINISELLO BALSAMO (MILAN) ACHIEVED THANKS TO THE TOP-PERFORMANCE OF AB SYSTEMS:
-24% -99% Fuel
Sulphur oxides
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The experience of the SMEC district heating plant
emissions in the surrounding environment, both the
in Cinisello Balsamo represents a particularly
carbon oxide values (NOx) ad carbon monoxide (CO)
important case history that allows us to understand
values, respectively estimated as 50 mg and 40 mg,
the opportunities and advantages offered by district
are well below the legal limits, which must be lower
heating, particularly if, in terms of technology
than 100 mg for NOx and 200 mg for CO.
adopted, we focus on the potential of cogeneration.
Also with regards the acoustic impact, 48 decibels
The collaboration between SMEC and AB provides
were estimated from cogeneration and 55 for the plant
concrete proof of how district heating can be decisive,
in an industrial area where limits are established
without necessarily having to use a large-scale plant.
as 70 decibels by day and 60 by night. In short, the
With regards to the Cinisello district heating network,
use of the cogeneration plant combined with district
the data is all too clear: savings of approximately
heating has absolutely no negative impact on the
24% on fuel have been calculated, along with a
territory. In addition to the advantages described
reduction of 99% of sulphur oxides, 49% of dust,
above, we also enjoy a significant economic return
28% of nitrogen oxide and a 27% reduction in carbon
for the local administration, deriving from the fees
dioxide. With regards to the possible outcome on the
for the concession to use public subsoil.
ERATION -49% -28% -27% Dust
Nitrogen oxide
Carbondioxide
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THE
From a technical-architectonic viewpoint too, the plant has been developed in complete respect of the environment. To this end, the project envisaged the burying of part of it in order to limit the height of the constructions on the road side, in full compliance with landscaping and environmental constraints. Respect of limits to emissions released into the atmosphere, which are well above legal parameters, is guaranteed by an elimination device and continuous monitoring system.
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E PROJECT SMEC DEVELOPED THE COMPLETE
Balsamo has authorized the development of the
PROJECT AND MANAGES THE PLANT IN CLOSE
district heating network by signing an agreement
COLLABORATION WITH THE CINISELLO LOCAL
granting permission for the use of its subsoil, in
COUNCIL.
response to public interest in energy, economic
The plant falls under a specific ‘Local Energy Plan’
and
drawn up by the Administration of Cinisello Balsamo
Multiservizi Energia Cinisello Balsamo) is a multi-
and destined to result in energy, and therefore
service company set up specifically to develop the
economic, savings for users, but above all to help
district heating network in Cinisello powered by a
decrease atmospheric emissions produced by the
cogeneration plant.
individual boilers. The local council of Cinisello
environmental
benefits.
SMEC
(Società
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The plant has been operative since October 2009,
Both the cogeneration engines and the boilers are
standing on an area measuring approximately
connected to chimney flues measuring approximately
2,700 square metres in the industrial estate to the
20 metres. The entire plant supplies energy to
northwest of the city of Cinisello Balsamo, on the
approximately 9 thousand medium-sized apartments
border with Muggiò. It allows for the simultaneous
and public buildings, such as the various schools of
production of heat and electricity, saving on fuel as
the area.
it uses part of the heat deriving from the electricity
The work was approved with the favourable opinion
generation process to produce thermal energy.
of all applicable competent authorities: Arpa, the
The plant was designed in the complex by
Provincial Authorities of Milan, the Fire Brigade, Asl3
professionals appointed by SMEC, whilst AB developed
health authorities and the safety at work service.
all the engineering aspects of the cogeneration part,
More specifically, the plant is equipped with a
consisting of two natural gas-fuelled engines, each
continuous emissions release monitoring and control
with an electrical power of 2,400 kW, allowing for the
system. The supply network is entirely underground,
thermal recovery of 2,600 kW, and four boilers, again
extending for 12 km. A collector runs parallel to the
fuelled by natural gas, each able to supply 7,800 kW.
network, in which all the subservices are located.
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2
4
Km district heating network
natural gas engines, each with a power of 2,400 kW
naturalgas boilers,eachable tosupply7,800kW thermalenergy
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The Cinisello Balsamo district heating network envisages three lots: complete installation will take three years, the first lot is currently operative (green line). By end 2010, the plant will connect 62 buildings for a total of 3,111 families.
9.000
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3
thousand private, public and cooperative housing users served
months to develop the plant
years to complete the network
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E
2xEcomax® 24 NGS Fuel consumption
Nm3/h
Power input
kW
5,534
Electrical power
kW
2,433
583
Electrical efficency
%
44.0
Hot water production return
°C
65
Delivery
°C kW
95 2,273
Thermal efficency
%
41.0
Total performance
%
85
P
For the district heating plant of Cinisello Balsamo, AB has supplied and installed two ECOMAX® 24 NGS cogeneration plants. The development of the district heating plant of
production at its Orzinuovi plants, installation
Cinisello Balsamo provides important evidence
and start-up in accordance with timescales
of how AB works and just what it can offer a
agreed with the customer, which, in this case,
customer with regards to this type of plant.
specified a fundamental date: the start of the
The case history shows, in fact, how AB is a
2009 thermal season to satisfy users who were
partner to the customer in all aspects of project
already connected.
development:
the
All this in addition to the availability of assistance
feasibility plan and optimisation of the ‘plant
and maintenance services provided directly by the
system’; proper technology engineering; plant
AB Service company.
collaboration
in
defining
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Ecomax
®
≤
PLANTS
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Alongside the supply of the cogeneration part of the plant, consisting of two ECOMAX速 24, AB also dealt with the many accessory works that were fundamental to optimal plant efficiency and reliability. More specifically, AB skills managed all the technical aspects in relation to plant systems, including the pump stations and expansion systems. non-cogeneration boilers were also installed with the relevant connection systems to the district heating network. The work carried out to eliminate fumes was also important, with the development and installation of special insulated chimneys. Engineering and installation of the electrical part of the entire plant, both in terms of the command/control cabins and to develop an integrated monitoring system of the release of emissions into the atmosphere. Amongst the other demands met, we should mention those in relation to the emergency generators and safety systems. NOx 20,000,00 15,000,00 10,000,00 5,000,00 0,00
Expected benefits NOx 25,000,00 20,000,00 15,000,00 10,000,00 5,000,00 0,00
CO 7,000,00 6,000,00 5,000,00 4,000,00 3,000,00 2,000,00 1,000,00 0,00
SO2
CO2
450,00 400,00 350,00 300,00 250,00 200,00 150,00 100,00 50,00 0,00
200,000,000,00 180,000,000,00 160,000,000,00 140,000,000,00 120,000,000,00 100,000,000,00 80,000,000,00 60,000,000,00 40,000,000,00 20,000,000,00 0,00
7,000,00 6,000,00 5,000,00 4,000,00 3,000,00 2,000,00 1,000,00 0,00
25,000,00
DUST
FUMES
CO
14,000,00 12,000,00 10,000,00 8,000,00 6,000,00 4,000,00 2,000,00 0,00
25,000,000,00 20,000,000,00 15,000,000,00 10,000,000,00 5,000,000,00 0,00
Current scenario Future scenario
FUMES 200,000,000,00 180,000,000,00 160,000,000,00 140,000,000,00 120,000,000,00 100,000,000,00 80,000,000,00 60,000,000,00 40,000,000,00 20,000,000,00 0,00
DUST 450,00 400,00 350,00 300,00 250,00 200,00 150,00 100,00 50,00 0,00
NOx: Nitrogen oxides CO: Carbon monoxide CO2 : Carbon monoxide SO2: Sulphur oxides
SO2
CO2 25,000,000,00 20,000,000,00 15,000,000,00 10,000,000,00 5,000,000,00 0,00
Current scenario
14,000,00 12,000,00 10,000,00 8,000,00 6,000,00 4,000,00 2,000,00 0,00
NOx: Nitrogen oxides
CO: Carbon monoxide The pollutant that have already Futureemissions scenario CO : Carbon monoxide SO : Sulphur oxides been avoided are: SO2 3,000 kg/year Fine dust 53 kg/year NOx 1,500 kg/year CO2 400 kg/year CO2 1,400,000 kg/year Fumes 11,000,000 kg/year 2
2
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Meticulous compliance with the strict supply timetable agreed with the customer. WORKS SCHEDULE Year 2009 2010 Month February March April May June July August September October November December January Week 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 1 2 3 4 Design Pre-manufacture in the workshop Power plant design Pre-manufacture in the workshop Assembly Start-up Continuous operation
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PLANT PERFORMANCE IN THE WORDS OF THOSE USING IT.
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What led you to choose cogeneration and the collaboration with AB? “The entrepreneurial and technical staff currently working in SMEC has matured significant experience in the design and development of district heating networks, and were able to assess the validity of choosing cogeneration as the best solution by which to optimise the plant’s thermal efficency. More specifically, cogeneration allowed us to obtain the constant basic thermal energy necessary to the network in optimal efficiency conditions. The thermal energy originating from the cogeneration plant forms the ‘hard core’ of the heat that always remains active and available. Cogeneration plants are, alone, sufficient to allow for the functioning of the district heating network for much of the year. At the coldest times, or where specific requirements exist, we use natural gas-powered boilers. With AB we developed a plant in Rho, in very similar conditions to those of Cinisello. At that time we were able to note with great satisfaction, the skill and willingness to collaborate towards achieving the very best results, starting from the specific logistical conditions and needs of the social context in which the plant was to be developed. With the staff of AB we were able to complete exactly the plant we were looking to obtain in Cinisello, in terms of characteristics and performance, within the scheduled timescale. We have found AB to be a multi-disciplinary system integrator able to offer a truly turnkey solution that goes well beyond the simple supply of a cogeneration plant. We have found a problem-solving reality that was able to intervene competently in the many technical specificities existing during the fitting-out of a plant such as this one”.
Now that the plant is fully functioning, are you happy with the results achieved? “We are very happy indeed with the work completed and how the results are showing that this was the right choice, demonstrating the validity of a project that we strived tenaciously to attain. The plant has proved itself to be of great value to the entire community of Cinisello. Right from the very first thermal season, the benefits were clear, both in terms of service commodity and with regards to optimising energy costs that, we should not forget, also means less need for maintenance of individual boilers. We should also then remember that the plant allows for a significant elimination of polluting substances due to the many boilers, often using obsolete technology or maintained poorly”. To what extent can the district heating plant be considered a ‘pilot project’? “It is a pilot project from every point of view: technology, dimensions, performance and scale economy. The SMEC network and plant thereby shows just what can be done in critical areas from a town planning and co-environmental viewpoint. Up until a short while ago, it was thought that district heating was only suitable for large communities and cities: today, the benefits of focussed action on a local level are clear to all. The first to realise it are the local administrations, who at the same time can note with great satisfaction just how useful it can be to begin public-private collaborations on the matter”.
Eng. Silvio Vezza (Operative Manager SMEC)
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AB SETS THE COGENERATION STANDARDS GLOBALLY been operating for over 30 years in the sector of cogeneration and promotion of energy from renewable sources.
AB is currently made up of 24 companies and over 500 employees and is a single entity able to manage the entire manufacturing cycle of a cogeneration plant: consultancy, design, production, installation and start-up with a comprehensive service. This has enabled AB to acquire unparalleled know-how, to become acquainted with every product detail and to provide a top-quality and highly-effective aftersales service. The success of AB which has already designed and built more than 900 plants - stems from ongoing investments in cutting-edge technologies, from the constant training and professional specialisation of all operators and from the development of an absolutely unique engineering
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department: a team of over 110 engineers engaged in developing the industry towards the production of increasingly more reliable and higher performance plants. AB cogeneration plants are distinguished by modularity, compactness and ease of transport and cater to the energy requirements of a number of different companies. Outright leader in Italy, AB is also expanding globally: in Spain (2007), in Romania (2009), in Poland (2010), and again with the opening of subsidiaries in Croatia and Serbia (2011). From 2012 AB is in Czech Republic, from 2013 also in the Netherlands, Austria, Brazil, Francia and Canada. From 2014 AB in UK, Germany, USA and Israel and from 2015 in Russia and Turkey too.
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Cogeneration has proven to be a winning choice, also in other industrial and non-industrial fields, such as food chemical, pharmaceutical, textile, plastic, paper, brick, etc. 700 customers, some of them are: Amadori, Benetton, BNL, Buitoni, Cartiere Saci, Coca - Cola, Cotonificio Albini, Eridania, Esselunga, Fatro, Ferrero, Felli Color, Galbani, Garda Plast, Granarolo, Gruppo Cremonini, Gruppo Mapei, kraft, Lafarge, Lilly, Martini & Rossi, Nestlè, Orogel, Pastificio Garofalo, Pastificio Rummo, Peroni, Pfizer, Polynt, Spumador, Wienerberger, etc.
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